Position corrected pulse width modulation for brushless direct current motors

ABSTRACT

A method of operating a brushless direct current motor is provided that generates a rotor position dependent pulse width modulation waveform. The waveform can improve motor efficiency and reduce torque variation.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.13/598,957, filed Aug. 30, 2012, and entitled “POSITION CORRECTED PULSEWIDTH MODULATION FOR BRUSHLESS DIRECT CURRENT MOTORS,” which is acontinuation-in-part of International Patent Application Serial No.PCT/US2011/026743, filed Mar. 1, 2011, and entitled “POSITION CORRECTEDPULSE WIDTH MODULATION FOR BRUSHLESS DIRECT CURRENT MOTORS,” whichclaims priority to U.S. Provisional Patent Application Ser. No.61/309,791, filed Mar. 2, 2010, and entitled “POSITION CORRECTED PULSEWIDTH MODULATION FOR BRUSHLESS DIRECT CURRENT MOTORS,” the entirecontents of each of which are hereby incorporated by reference for allpurposes.

FIELD

This description is directed to motor controllers for brushless directcurrent motors. In particular, a system and method for generating pulsewidth modulated motor control commands is disclosed.

BACKGROUND AND SUMMARY

Pulse width modulation (PWM) is a common technique used to control theaverage speed of brushless direct current (BLDC) motors. Direct currentmotors have a characteristic that their speed is nearly linearlyproportional to the average voltage applied across the motor windings.In a PWM controlled motor, a PWM waveform is used to control switchesconnecting the motor windings to a power supply. This is done in such away that the average voltage across the motor is equal to the PWM dutycycle multiplied by the voltage of the power supply. Linear voltageregulators are also used to vary the DC voltage across BLDC motors; butthey have the disadvantage of power losses across their pass elements.

PWM control signals are pulse trains where the duty cycle of the signalis defined as the average time high divided by the period. The period ofthe PWM control signal is typically chosen to be much smaller than therotational period of the motor. Thus, many PWM pulses may occur withinone rotation of the motor; and the pulses of equal width (duration) areevenly distributed throughout the motor rotation.

Torque and motion in BLDC motors are a result of the attraction andrepulsion between the magnetic poles on the rotor and stator. The torqueis a function of the magnetic field strength between the rotor andstator poles, as well as the geometry of the motor, and the relativeangular position between the rotor and stator. In BLDC motors themagnetic pole orientation (and current) of the windings is reversedusing commutation switches which replace the split ring commutator foundin brushed motors. In order to avoid shorting out the power supply,there is a short commutation delay between when the winding currentflowing in one direction is turned off, and the time before current isturned on in the other direction. This is analogous to the gap in thesplit ring commutator of brushed motors.

Applying a uniform PWM pulse train to control the speed of a BLDC motorhas several disadvantages. For example, the energy is applied in thesame manner throughout one rotation of the rotor and therefore fails torecognize physical differences in the motor that are related to rotorposition. Thus, applying power to a motor in this manner can producenon-uniform torque output from the motor, increased audible noise fromthe motor, and energy losses that are higher than is desirable.

The inventor herein has recognized the above-mentioned disadvantages andhas developed a method for improving motor control. In one embodiment ofthe present description, a method for controlling a brushless directcurrent motor, comprising: generating a motor command signal during acommutation interval of said brushless direct current motor; andadjusting a common attribute of at least two non-zero pulses of saidmotor command signal such that said at least two non-zero pulses of saidmotor command signal are not uniform.

By adjusting the width of pulses that make up a motor command signalduring a commutation period of a motor cycle, operation of a motor maybe improved. In particular, adjusting pulse widths of individual pulsesthat form a pulse train delivering energy to a motor can improve motorefficiency, reduce motor audible noise, and improve torque outputcharacteristics of the motor. In one example, the first few pulses thatare included in the pulse train of a motor commutation interval have ashorter duration (e.g., the amount if time a signal is high is shorterthan the amount of time the signal is low during the period of a pulse).As the commutation interval continues, the pulses increase in durationfor a time during the motor commutation interval. Finally, the pulseduration is decreased near the end of the motor commutation interval.This pulse train generating strategy can account for the position ofmotor poles during motor rotation in adjusting the pulse width so thatattraction and repulsion between motor poles is improved and made moreefficient, at least during some conditions.

The above advantages and other advantages, and features of the presentdescription will be readily apparent from the following DetailedDescription when taken alone or in connection with the accompanyingdrawings.

It should be understood that the summary above is provided to introducein simplified form a selection of concepts that are further described inthe detailed description. It is not meant to identify key or essentialfeatures of the claimed subject matter, the scope of which is defineduniquely by the claims that follow the detailed description.Furthermore, the claimed subject matter is not limited toimplementations that solve any disadvantages noted above or in any partof this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter of the present disclosure will be better understoodfrom reading the following detailed description of non-limitingembodiments, with reference to the attached drawings, wherein:

FIG. 1 is a block diagram of a motor control integrated circuit (IC) ina typical brushless direct current (BLDC) motor application.

FIG. 2 is a more detailed block diagram of FIG. 1, showing greaterdetail of the motor control IC, the BLDC motor and the commutationswitches.

FIG. 3 is a block diagram showing in greater detail the time segmentgenerator and pulse width modulation (PWM) generator blocks of FIG. 2.

FIG. 4 is a timing diagram showing the relation of the rotor angle, themagnetic pole closest to the Hall Effect sensor, the Hall Amplifieroutput, the PWM waveforms, and the pre-driver outputs.

FIG. 5 is a timing diagram showing how a PWM waveform is generated usingan oscillator, a control signal and a comparator.

FIG. 6 is a timing diagram showing the relation between positioncorrected PWM waveforms and the rotor angle.

FIG. 7 is a flow chart of an embodiment of a method for controlling whena position dependent speed control gets enabled.

FIG. 8 is an oscilloscope plot comparing the motor current waveforms ofan actual BLDC motor with the position corrected PWM enabled anddisabled.

FIG. 9 is a block diagram showing another embodiment of the PWMgenerator block of FIG. 2 that includes a multi-dimensional ROMcorrection table.

DETAILED DESCRIPTION

FIG. 1 shows a block diagram of a typical application for a motorcontrol integrated circuit 100. In this example the brushless directcurrent (BLDC) motor 102 is a cooling fan, although it could be any BLDCmotor. In the cooling fan application a temperature sensor 104 reportsthe system temperature to motor control integrated circuit (IC) 104 inthe form of a speed control signal representing the desired speed forthe fan. The differential output of a Hall Effect Sensor 106 getsamplified by a Hall Amplifier 108 to determine how the rotor's magneticpoles, north and south, are oriented with respect to the stator.Commutation Switches 110 connect the fan's motor windings to the powersupply (labeled V_(DD)) and ground. The motor control IC 100 uses themagnetic pole information together with Commutation Logic block 112,Pre-Driver 114, and Commutation Switches 110 to commutate the current inthe stator windings. A pulse width module (PWM) Generator 116 adjuststhe PWM duty cycle to the switches in order to set the average voltageacross the fan motor. As the rotor turns, the motor control IC 100 usesan internal clock and timer to determine the frequency of thecommutation which represents the actual speed of the fan. Knowledge ofthe actual speed of the fan can be used in a closed loop fashion toadjust the PWM duty cycle until the fan's actual speed equals thedesired speed set by the temperature sensor 104.

The temperature sensor 104 may be a simple thermistor or a complexdigital system. The speed control signal can be in the form of a directcurrent (DC) voltage, a digital control word, or a PWM signal; eachrepresenting the desired speed of the cooling fan. In the followingdiscussion, for simplicity, it is assumed the speed control signal is aDC voltage. The Commutation Switches 110 are typically configured as anH-Bridge; but can also be configured differently for different coilwinding configurations. The Commutation Switches 110 could be integratedinto the motor control IC 100; but for illustrative purposes are shownexternally. In one embodiment, the motor control IC 100, the CommutationSwitches 110, and the Hall Effect Sensor 106 along with the rotor andstator windings are all physically contained within the cooling fan.

A more detailed block diagram of the motor control IC 100 is shown inFIG. 2 along with expanded views of the commutation switches 110 andBLDC motor 102 illustrated with a single phase winding. The commutationswitches 110 are configured as an H-Bridge. The Time Segment Generator118 and the PWM Generator 116 form the motor commands for driving theH-Bridge circuitry. These two blocks are shown in greater detail in FIG.3. However, before explaining these blocks, the other blocks in FIG. 2are described first beginning with the motor 102.

The permanent magnet rotor is shown with two pole pairs with the poleslabeled N for north and S for south. In general, any number of polepairs can be used. As the rotor spins, the rotor's magnetic pole closestto the Hall Effect sensor transitions from north to south and backagain.

The Hall Effect Sensor's differential outputs are labeled Hall+ andHall−. When the rotor is spinning with a constant angular velocity, thedifferential output Hall+ minus Hall− is nearly sinusoidal with anamplitude of a few hundred millivolts. This small differential signal isamplified by the Hall Amplifier 108 and is interpreted by the MotorControl IC 100 as north and south rotor position. The amplified Hallsignal is pinned out of the IC as an open drain output on the Tach(tachometer) pin. As the rotor spins the Tach signal toggles between alogical one and zero. The rate at which this happens indicates the speedof the motor.

Commutation Logic 112 decodes the polarity information of the HallAmplifier output; and is used to determine which of the pre-driver andH-Bridge driver switches gets turned on, and ultimately the direction ofcurrent flow in the stator windings.

The stator windings are coupled to the power supply through the H-Bridgeswitches and a resistor to ground. The power supply voltages are labeledV_(DD) and Ground. The two PMOS switches are labeled S1T and S2T forswitch 1 top and switch 2 top respectively. Likewise, the two NMOSswitches are labeled S1B and S2B switch 1 bottom and switch 2 bottomrespectively. When a rotor pole closest to the Hall Effect Sensor hasnorth polarity, H-Bridge switches S1T and S1B will conduct causingcurrent to flow in one direction through the windings. When a rotorsouth pole is closest to the Hall Effect sensor, H-Bridge switches S2Tand S2B conduct causing the current in the windings to flow in the otherdirection. Reversing the direction of the winding current will cause thestator magnetic poles to reverse polarity. As the rotor turns, thereversing of the stator winding current is known as commutation. Inorder to avoid shorting out the power supply to ground duringcommutation, only one pair of switches is allowed to be on at a time.There is a small delay known as commutation delay between when one pairof switches turns off and the other pair of switches turns on.

The pre-driver block 114 of FIG. 1 has been expanded into two differentblocks in FIG. 2. The pre-driver block labeled “Commutation” controlsthe PMOS H-Bridge switches S1T and S2T. The output pins are labeledGate1T and Gate2T because they are the voltages on the gates of the PMOSswitches S1T and S2T. In a typical H-Bridge application, the topswitches are not controlled with PWM and only transition at thecommutation frequency. Because PMOS transistors are used in this examplefor the top H-Bridge switches; they conduct when their gate voltages arelow.

The second pre-driver block is labeled “Commutation & PWM”. It controlsthe NMOS H-Bridge switches S1B and S2B. The output pins are labeledGate1B and Gate2B because they are the voltages on the gates of the NMOSswitches S1B and S2B. Gate1B transitions at the PWM frequency when therotor Hall amplifier reports north and is held low otherwise. Gate2Btransitions at the PWM frequency when the Hall amplifier reports southand held low otherwise.

In one embodiment, a control IC provides several degradation protectionfeatures built in for the safety of the motor. Referring back to FIG. 2,the Output Enable block 120 enables the bottom NMOS H-Bridge switches toconduct current only if no degradation conditions exist. If a conditionof degradation occurs, the bottom switches in the H-Bridge are turnedoff, disabling current to the motor windings. In the example of FIG. 2,three degradation conditions are detected which can disable the motor:rotor lock, thermal overload, and current overload. The Rotor LockDetect block 122 monitors the Hall Amplifier output and uses theinternal clock to measure the rotor speed. If the rotor speed fallsbelow a preset threshold, it is assumed there is a blockage stopping therotor and the motor is disabled before unsafe current levels build up inthe windings. The motor Control IC 100 has its own thermal sensorlocated inside the Thermal Protection block 124. As the Motor Control IC100 is typically located inside the motor, the IC temperature is anindication of the motor temperature. If the IC temperature rises above athreshold temperature, the motor is disabled. Finally, the statorwinding current is sensed across a resistor between the over currentprotection (OCP) pin and ground. The Over Current Protection block 126monitors the stator winding current. If the current exceeds apredetermined safety limit, then the motor is disabled.

The speed control input tells the Motor Control IC 100 the desired speedof the motor. In certain applications, it is desired that the speed ofthe motor never drop below a specified level. The minimum speed input isan extra speed control input which can be used to set this minimumallowed speed. The Motor Control IC 100 has a voltage reference outputpin labeled Vref. The minimum speed can be set using a resistor dividerbetween the Vref pin and ground. The Maximum Select block 128 chooseswhich of the two speed control inputs will be used to control the speedof the motor; either the minimum speed input or the speed control input.If the voltage labeled “speed control” falls below the voltage on theminimum speed pin, then the minimum speed input will be used.

An optional Closed Loop Control block 130 is shown in dashed lines. Asthe rotor turns, an internal clock and timer determine the frequency ofthe commutation which represents the motor's actual speed. The ClosedLoop Control block 130 can dynamically adjust the input to the PWMGenerator 116 until the motor's actual speed equals the motor's desiredspeed as defined by the output of the Maximum Select block 128. Ifclosed loop control is not used, the output of the Maximum Select block128 is passed directly to the PWM Generator 116. The output of theClosed Loop Control block 130 (input to the PWM Generator) is labeled“Closed Loop Speed Control” in FIG. 3.

FIG. 4 shows the relative timings of the rotor angle, the magnetic poleclosest to the Hall Effect sensor, the Hall Amplifier output; the PWMwaveforms, and the pre-driver outputs Gate1B, Gate2B, Gate1T, andGate2B. FIG. 4 also compares an example of traditional PWM waveformswith position corrected PWM waveforms. The traditional PWM waveformshave uniformly distributed pulses with the same pulse width. On theother hand, the position corrected PWM waveforms in this descriptionhave varying duty cycles dependent on the rotor position. Rotor movementand torque in DC motors are based on the magnetic attraction andrepulsion between the stator and rotor. The magnitude of the torque isangularly dependent based on the geometry of the motor. A uniformlydistributed PWM waveform will result in wasted energy being applied tothe motor during times of minimum torque. The wasted energy shows up ascurrent spikes in the motor windings and excess heat.

In contrast, the position corrected PWM method generates a motor commandsignal during a commutation interval of said brushless direct currentmotor, and adjusting a common attribute of at least two non-zero pulsesof said motor command signal such that said at least two non-zero pulsesof said motor command signal are not uniform. The common attribute maybe a pulse width or a pulse amplitude. In one embodiment, the firstpulse of the two non-zero pulses has a shorter duration high level pulsewidth than the second pulse. And, a third non-zero pulse during saidcommutation interval, the third non-zero pulse produced after saidsecond pulse, the third non-zero pulse having a shorter duration highlevel pulse width than said second pulse may also be provided. Inaddition, the common attribute is adjusted in response to a position ofsaid brushless direct current motor in one embodiment. Further, theposition of said brushless direct current motor is converted into a timesegment counter signal, and the time segment counter signal is modifiedby a correction and converted to an analog signal. And, the analogsignal is multiplied by a speed control adjustment and compared to anoscillating signal before being output to said brushless direct currentmotor as discussed below. In one embodiment, the brushless directcurrent motor is a fan motor and a motor command correction is selectedfrom a plurality of correction profiles in response to an operatingparameter. Further still, the adjustment of the common attribute isdeactivated in response to a condition of degradation. For example, theadjustment of the common attribute is deactivated in response to acondition of degradation of the motor. This approach results in lessenergy being required to run the motor at any given speed. This approachalso allows for less torque variation within one rotation resulting inless audible noise.

As may be readily determined from the description, a method forcontrolling a brushless direct current motor is provided, comprising:generating a signal indicative of a position of a brushless directcurrent motor, and generating a motor command signal from said signalduring a commutation interval, said motor command signal comprising atleast two non-zero pulses where at least one common attribute of each ofsaid two non-zero pulses is different between the two non-zero pulses.

Although FIG. 4 shows PWM waveforms, it will be appreciated that anysuitable pulse train attribute may be modulated alone or in combinationwith the pulse width (or duration) to provide a position corrected motorcontrol signal. For example, amplitude of a pulse train may be variedbased on rotor position as described above. In this way, energy and/orheat spikes may be eliminated in angular rotational ranges where torqueis greater so as to reduce energy usage and heat production.

Neglecting improvements in motor performance, the average value of apulse train attribute that is varied over a commutation interval isequal to an average value of a pulse train attribute that is not variedover the commutation interval. In other words, although a pulse widthattribute may be varied over a commutation interval, the average valueof that pulse train attribute tracks an average value of a waveform thatis not varied.

The two remaining blocks of FIG. 2 are the Time Segment Generator 118and the PWM Generator 116. More detailed block diagrams of these twoblocks are illustrated in FIG. 3. Together these blocks generate theposition corrected PWM waveforms of FIG. 4; and represent the core ideasof the present disclosure.

Inside the PWM Generator of FIG. 3 is an oscillator 302 that generates atriangle waveform. An analog comparator 304 is used to compare thetriangle wave against the position corrected speed control voltage. Theoutput of the comparator is high when the position corrected speedcontrol voltage is larger than the triangle voltage. This results in theposition corrected PWM signal at the output of the comparator. Thetiming diagram of FIG. 5 shows the analog voltages of this comparisonand the resulting PWM waveform. In some embodiments, the triangle waveoscillator and analog comparator may be replaced with a high frequencyclock and a counter to generate a digitized PWM waveform. For thepurpose of this disclosure analog voltages are illustrated for clarity.Among other disclosure, the present description includes generation of aposition corrected speed control signal, and results in the positioncorrected PWM waveforms of FIG. 4.

The relation between the waveforms of the Time Segment Generator 118 andPWM Generator 116 of FIG. 3 are illustrated in the timing diagram ofFIG. 6. Note in this timing diagram the rotor slows down between 270°and 360°. This is done to emphasize the rate at which the Time SegmentCounter steps through the time segments, and is based on the timebetween previous Hall edges.

The Hall amplifier output reports when the rotor's magnetic pole closestto the Hall Effect sensor transitions from north to south and back againas the rotor spins. As shown in FIG. 6, the rising and falling edges ofthe Hall Amplifier output are edge detected at times t₁, t₂, t₃ and t₄.Without the use additional sensors, these are the only times the rotorposition is known with any certainty as the rotor spins. However, therelative change in rotor position after a hall edge occurs can becalculated with knowledge of the rotor's angular velocity and the timethat has lapsed since the last edge was detected. Let θ be the rotorangle at time t, let t_(k) and t_(k-1) be the times of the previous twoHall edges, and let θ_(k) be the rotor angle at time t_(k). If the rotoris moving with a constant angular velocity then the change in rotorangle can be calculated as

${\theta - \theta_{k}} = {\frac{t - t_{k}}{t_{k} - t_{k - 1}}*\frac{360{^\circ}}{2*P}}$

Where P equals the number of magnetic pole pairs in the rotor. For thetwo pole pair rotor shown in FIG. 2, the change in rotor angle for timet between t₂ and t₃ can be calculated as

${\theta - \theta_{2}} = {\frac{t - t_{2}}{t_{2} - t_{1}}*90{^\circ}}$

The Time Segment Generator 118 in FIG. 3 divides the time between theprevious two Hall edges is divided into 2^(N) equal length timesegments, where N is the number of bits in the ROM Correction Tableaddress. These time segments correspond to 2^(N) discrete angularpositions between 0° and 90°. The internal clock increments the TimeSegment Counter 306 through the 2^(N) time segments at a rate determinedby the speed of the rotor as recorded by the time between the two mostrecent Hall edges. The binary output of the Time Segment Counter 306 isused as the address word for the ROM Correction Table 308. The ROMCorrection Table 308 stores a different binary correction factor(calibration word) for each of the 2^(N) time segments. The binarycorrection factors are input to the digital to analog convertor (DAC)310. The DAC 310 converts the binary correction factors into analogvoltages. As the Time Segment Counter 306 steps through the 2^(N) timesegments, the DAC 310 outputs a staircase shaped analog correctionwaveform. In FIG. 6, the output of the ROM correction table is shownwith binary units; and the output of the DAC is shown with voltageunits.

The closed loop speed control input to the PWM Generator 116 of FIG. 3is multiplied by the output of the DAC 310. In FIG. 6, the closed loopspeed control voltage has four different amplitudes illustrating fourseparate examples of how the closed loop speed control voltage getsmultiplied by the DAC output resulting in the position corrected speedcontrol voltage. In normal steady state operation with the motor runningat a constant speed, the closed loop speed control voltage will be aconstant DC voltage, and will not vary as the rotor spins. The output ofthe multiplier is the position corrected speed control signal. This timevarying position dependent analog voltage is then compared against theoscillator triangle wave to generate the position corrected PWM.

The Time Segment Generator 118 of FIG. 3 can be explained as follows.The Edge Detect block 312 marks in time when the rotor pole closest tothe Hall Effect transitions from north to south and from south back tonorth. The internal clock, together with the Hall edge counter 314measures the time between the last two Hall edges. This time is storedin the Latch 316 in the form of a binary count. The count is divided by2^(N) and is held at the output of the divider 318 until the next Halledge occurs (at which time it is updated). The output of the divider 318is a binary word representing the duration of one time segment. TheDiscrete Time Interval Counter 320 is reset to zero at every Hall edge.It is allowed to count until its value reaches the value held at theoutput of the Divider 318. When this occurs, the Comparator 322increments the Time Segment Counter 306 and resets the Discrete TimeInterval Counter 320 back to zero. The Discrete Time Interval Counter320 immediately starts counting again. This repeats until the TimeSegment Counter 306 reaches a count equal to 2^(N)−1 at which timeeverything stops. All counters are reset to zero at the next Hall edgeand the process repeats itself.

Thus, the present description includes an integrated circuit (IC)comprising: a time segment generator that produces binary output from adivided position signal of a brushless direct current motor; and a pulsewidth modulation generator including a correction section that storescorrection factors for binary output produced by said time segmentgenerator, a digital to analog converter, an oscillator, and acomparator. In one embodiment, the position from a Hall Effect sensorcoupled to said brushless direct current motor provides a signal that isconverted into said divided position signal of said brushless directcurrent motor. Further, the time segment generator is further comprisedof an edge detector that marks the last two Hall edges received from theedge detector, a latch to store the time received from the edge counteras a binary count, a divider to divide the binary count according to anumber of bits in a correction factor table to provide a duration of onetime segment, and a time segment counter to provide said binary outputby incrementing through the time segments of the correction table at arate determined by the time between the last two Hall edges. Furtherstill, the correction section includes a factor table to receive thebinary output from the time segment generator and provide a binarycorrection factor corresponding to each time segment of the motorcontrol signal, a digital to analog converter to convert the binarycorrection factor corresponding to each time segment of the motorcontrol signal into time varying position dependent analog voltages, anda comparator to compare the time varying position dependent analogvoltage against an oscillating triangle wave to generate the positioncorrected pulse width modulated motor command signal. And, thecorrection factor table includes a plurality of correction factorprofiles corresponding to each time segment of the binary output, andone of the plurality of correction factor profiles is selected based onat least one operating parameter. Further still, the digital to analogconverter is disabled in response to an operating condition to providethe motor command signal without position corrected pulse widthmodulation.

FIG. 7 is a flow chart of an embodiment of a method 700 for controllingwhen the position dependent speed control gets enabled. Specialprecautions are needed during degradation conditions and when power isfirst applied to the motor. If zeros are stored as calibration words inthe ROM Correction Table 308, it is possible that the initial DAC outputof zero volts will result in an initial position corrected PWM of zeropercent duty cycle. If this happens the motor may not spin. To reducethe possibility of this from happening, a startup sequence is neededsuch that the DAC 310 is initially disabled.

At 702, power is applied to the motor 102 (and the motor control IC 100)at a startup or reset condition. At 704, the power on reset signaldisables the DAC output. By disabling the DAC output variance of a pulsetrain attribute (e.g., pulse width) is disabled and a motor controlsignal with a fixed pulse width is produced.

After which, at 706, the Hall Amplifier output is constantly monitoredto determine the rotor speed. At 708, it is determined if the rotor isspinning faster than a predetermined speed. If so, at 710, the DACoutput is enabled to vary the pulse train attribute resulting inposition corrected PWM. In some cases, enabling the DAC outputre-enables the variance of the pulse train attribute. Otherwise, the DACremains disabled and the method returns to 706.

At 712, after the DAC output is enabled, the Hall Amplifier output ismonitored to determine the rotor speed. At 714, it is determined if therotor is spinning faster than the predetermined speed. If so, the DACremains enabled and the method returns to 712. If not, the methodreturns to 704 where the DAC is disabled.

Conditions of degradation may result in the rotor coming to a completestop. At 716, a degradation condition is detected and the method movesto 704 where the DAC is disabled. Therefore, all conditions ofdegradation automatically disable the DAC until the rotor startsspinning again and rotor speed becomes greater than a predeterminedthreshold speed at which time the variance of the pulse train attributeis re-enabled. Accordingly, the DAC may be disabled in response to avariety of operation conditions including degradation conditions,startup, and/or reset conditions, then re-enabled to ensure operation ofthe motor.

Thus, the present method can control a brushless direct current motor ata startup or reset condition, generate a motor command signal at a fixedpulse width over a selected angular rotational range of the brushlessdirect current motor, and in response to a rotor speed of the brushlessdirect current motor being greater than a predetermined threshold speed,varying the pulse width of the motor command signal between a firstnon-zero state and a second non-zero state over the selected angularrotational range. In addition, varying includes decreasing the pulsewidth during a first angular rotational range of the commutationinterval, then increasing the pulse width during a second angularrotational range of the commutation interval, and then decreasing the atleast one pulse train attribute during a third angular rotational rangeof the commutation interval. Further, in one embodiment, the rotortorque of the brushless direct current motor in the second angularrotational range is greater than in the a first angular rotational rangeand the third angular rotational range. Further still, in oneembodiment, the pulse width variance is disabled in response to acondition of degradation, then re-enabling variance of the pulse widthin response to the rotor speed of the brushless direct current motorbeing greater than a predetermined threshold speed.

Some applications may require a DAC enable signal to be pinned out as aninput to the motor control IC. This option would give the systemdesigner more flexibility in the control of the motor. Disabling the DACwould allow for a higher achievable maximum speed for a given powersupply voltage.

FIG. 8 is an oscilloscope plot comparing actual winding currentwaveforms of a brushless DC motor with the position corrected PWMenabled and disabled, operating at the same speed, and under the sameoperating conditions. This comparison was made possible with the use ofa DAC enable pin on the motor control IC. The top waveform shows thecurrent spikes that occur when traditional PWM waveforms are used tocontrol the speed of the motor. These current spikes result in wastedenergy and heat in the motor windings. The bottom waveform shows thecurrent spikes eliminated with the use of position corrected PWMresulting in more energy efficient operation at the same speed. The ROMcode correction controlling the DAC is used to correct the waveshape ofthe motor current.

The choice for correction factors stored in the ROM may vary based onthe physical design of the motor, and which performance characteristicsare being optimized. For example, the ROM code that optimizes energyefficiency may not be the same code that minimizes torque variation ornoise. Also, the optimal code may vary based on the speed of the rotoror on environmental conditions such as temperature, pressure, humidity,and loading, among other things. It may be desirable to optimizedifferent performance characteristics under different conditions.Accordingly, varying a pulse train attribute of the motor control signalmay include selecting one of a plurality of correction factor profilesbased on at least one operating parameter. For example, it may bedesirable for a motor to operate with minimum torque variation at slowerspeeds, while it operates with greater energy efficiency at higherspeeds. Example predefined correction factor profiles may include atorque optimization profile, a noise optimization profile, a speedoptimization profile, and a maximum energy efficiency profile, etc.

To accommodate these possibilities, a multi-dimensional ROM correctiontable can be used with pointers based on as many parameters (e.g. speedand environmental parameters) as needed by the application. Eachcombination of parameters could have a separate ROM lookup table. FIG. 9shows an example of this. FIG. 9 is the similar to FIG. 3 except the PWMGenerator Block has been modified to accommodate the multi-dimensionalROM 900. The Decoder 902 chooses which portion of the ROM correctiontable 900 will be used based on the actual speed of the rotor and on theenvironmental conditions, or other input parameters.

The degree to which a performance characteristic is optimized may bemade arbitrarily precise by increasing, the number of time segments Nproduced by the Time Segment Generator, and by increasing the number ofbits used for each digital correction factor stored in the ROM lookuptable.

Applications include but are not limited to reducing power consumptionin portable devices using brushless DC motors, such as laptop computers,in order to reduce heat and extend battery life. Another application isto reduce audible noise generated by appliances used in noise sensitiveenvironments.

1. An integrated circuit (IC) comprising: a time segment generator thatproduces binary output from a divided position signal of a brushlessdirect current motor; and a pulse width modulation generator including acorrection section that stores correction factors for binary outputproduced by said time segment generator, a digital to analog converter,an oscillator, and a comparator.
 2. The IC of claim 1, wherein aposition from a Hall Effect sensor coupled to said brushless directcurrent motor provides a signal that is converted into said dividedposition signal of said brushless direct current motor.
 3. The IC ofclaim 1, wherein said time segment generator is further comprised of anedge counter that marks the last two Hall edges received from the edgedetector; a latch to store a time received from the edge counter as abinary count; a divider to divide the binary count according to a numberof bits in a correction factor table to provide a duration of one timesegment; and a time segment counter to provide said binary output byincrementing through time segments of the correction section at a ratedetermined by the time between the last two Hall edges.
 4. The IC ofclaim 1, wherein the correction section includes a factor table toreceive the binary output from the time segment generator and provide abinary correction factor to correct the motor current corresponding toeach time segment of a motor control signal; a digital to analogconverter to convert the binary correction factor corresponding to eachtime segment of the motor control signal into time varying positiondependent analog voltages; and a comparator to compare the time varyingposition dependent analog voltage against an oscillating triangle waveto generate the position corrected pulse width modulated motor commandsignal.
 5. The IC of claim 4, wherein the factor table includes aplurality of correction factor profiles corresponding to each timesegment of the binary output, and one of the plurality of correctionfactor profiles is selected based on at least one operating parameter,and wherein the digital to analog converter is disabled in response toan operating condition to provide the motor command signal withoutposition corrected pulse width modulation.
 6. An integrated circuit (IC)comprising: a time segment generator that produces binary output from adivided position signal of a brushless direct current single phasemotor; and a pulse width modulation generator including a correctionsection that stores correction factors for binary output produced bysaid time segment generator, a digital to analog converter, anoscillator, and a comparator, the generator further receiving a power onreset signal that disables output variance of the digital to analogconverter and generating a motor command signal at a fixed pulse widthover a selected angular rotational range of the brushless direct currentsingle phase current motor, the generator monitoring whether rotor speedis greater than a predetermined threshold speed, and varying the pulsewidth of the motor command signal between a first non-zero state and asecond non-zero state over the selected angular rotational range, andfurther disabling variance of the pulse width in response to a conditionof degradation, then re-enabling variance of the pulse width in responseto the rotor speed of motor being greater than the predeterminedthreshold speed, wherein the selected angular rotational range is acommutation interval, and wherein varying includes decreasing the pulsewidth during a first angular rotational range of a commutation interval,then increasing the pulse width during a second angular rotational rangeof the commutation interval, and then decreasing at least one pulsetrain attribute during a third angular rotational range of thecommutation interval.
 7. The IC of claim 6, wherein a rotor torque ofthe motor in the second angular rotational range is greater than in thefirst angular rotational range and the third angular rotational range.8. The IC of claim 6, wherein a position from a Hall Effect sensorcoupled to said brushless direct current motor provides a signal that isconverted into said divided position signal of said brushless directcurrent motor.
 9. The IC of claim 6, wherein said time segment generatoris further comprised of an edge counter that marks the last two Halledges received from the edge detector; a latch to store a time receivedfrom the edge counter as a binary count; a divider to divide the binarycount according to a number of bits in a correction factor table toprovide a duration of one time segment; and a time segment counter toprovide said binary output by incrementing through time segments of thecorrection section at a rate determined by the time between the last twoHall edges.
 10. The IC of claim 6, wherein the correction sectionincludes a factor table to receive the binary output from the timesegment generator and provide a binary correction factor to correct themotor current corresponding to each time segment of a motor controlsignal; a digital to analog converter to convert the binary correctionfactor corresponding to each time segment of the motor control signalinto time varying position dependent analog voltages; and a comparatorto compare the time varying position dependent analog voltage against anoscillating triangle wave to generate the position corrected pulse widthmodulated motor command signal.
 11. The IC of claim 10, wherein thefactor table includes a plurality of correction factor profilescorresponding to each time segment of the binary output, and one of theplurality of correction factor profiles is selected based on at leastone operating parameter, and wherein the digital to analog converter isdisabled in response to an operating condition to provide the motorcommand signal without position corrected pulse width modulation.
 12. Anintegrated circuit (IC) system comprising: a brushless direct currentsingle phase motor; and a pulse width modulation generator including acorrection section that stores correction factors for binary output, adigital to analog converter, an oscillator, and a comparator, thegenerator further receiving a power on reset signal that disables outputvariance of the digital to analog converter and generating a motorcommand signal at a fixed pulse width over a selected angular rotationalrange of the brushless direct current single phase current motor, thegenerator monitoring whether rotor speed is greater than a predeterminedthreshold speed, and varying the pulse width of the motor command signalbetween a first non-zero state and a second non-zero state over theselected angular rotational range, and further disabling variance of thepulse width in response to a condition of degradation, then re-enablingvariance of the pulse width in response to the rotor speed of motorbeing greater than the predetermined threshold speed, wherein theselected angular rotational range is a commutation interval, and whereinvarying includes decreasing the pulse width during a first angularrotational range of a commutation interval, then increasing the pulsewidth during a second angular rotational range of the commutationinterval, and then decreasing at least one pulse train attribute duringa third angular rotational range of the commutation interval.
 13. The ICsystem of claim 12, wherein a rotor torque of the motor in the secondangular rotational range is greater than in the first angular rotationalrange and the third angular rotational range.
 14. The IC system of claim12, further comprising a time segment generator that produces binaryoutput from a divided position signal of the brushless direct currentsingle phase motor, wherein said time segment generator is furthercomprised of an edge counter that marks the last two Hall edges receivedfrom the edge detector; a latch to store a time received from the edgecounter as a binary count; a divider to divide the binary countaccording to a number of bits in a correction factor table to provide aduration of one time segment; and a time segment counter to provide saidbinary output by incrementing through time segments of the correctionsection at a rate determined by the time between the last two Halledges.
 15. The IC of claim 14, wherein the correction section includes afactor table to receive the binary output from the time segmentgenerator and provide a binary correction factor to correct the motorcurrent corresponding to each time segment of a motor control signal; adigital to analog converter to convert the binary correction factorcorresponding to each time segment of the motor control signal into timevarying position dependent analog voltages; and a comparator to comparethe time varying position dependent analog voltage against anoscillating triangle wave to generate the position corrected pulse widthmodulated motor command signal.
 16. The IC of claim 15, wherein thefactor table includes a plurality of correction factor profilescorresponding to each time segment of the binary output, and one of theplurality of correction factor profiles is selected based on at leastone operating parameter, and wherein the digital to analog converter isdisabled in response to an operating condition to provide the motorcommand signal without position corrected pulse width modulation.